Ortho training device

ABSTRACT

An article of manufacture, an orthodic device for use with feet and ankles with an arch support removably attached to an ankle brace. A stirrup, tab and tunnel are disclosed. 
     Optional pads may also be used with versions of the invention.

CROSS REFERENCE TO RELATED APPLICATIONS

This Nonprovisional application for patent incorporates by reference (tothe extent it does not conflict with the disclosure herein) and claimsthe benefit and priority of pending Provisional application filed 2 Sep.2011 with US Express Mail #EG 703426560 US entitled “Ortho TrainingDevice” commonly owned with the instant application.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document, including thedrawings and Appendices, contain material which is subject to copyrightprotection. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosureas it appears in the Patent and Trademark Office patent files orrecords, but otherwise reserves all copyright rights whatsoever.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Versions and embodiments of the present invention relate generally tofoot and ankle support devices. Specifically, versions of the inventionrelate to foot and ankle orthopedic devices that may be quickly changedand adapted to assist in faster healing times, better results andbenefits and new, useful and unobvious versions thereof.

2. Description/Background of the Related Art

The art discussed herein is not to be considered admitted prior art butis presented to more clearly discuss and describe what is still lackingin the earlier art.

Foot and ankle orthopedic devices are conventionally made as separatedevices. Ankle sprains usually require a bulky device to be worn at alltimes. Prior art devices must be worn either as an ankle device tosupport the joint during any and all ambulation or as a foot device forpes planus (flat feet) and/or other foot problems.

When both devices are needed for rehabilitation, one fitting is requiredfor the foot device and another separate fitting is needed for the anklebrace. This second required fitting wastes time for thepatient/user/operator/manufacturer. The process of bracing an individualfor medial (inside/interior)/lateral (outside/exterior) support iswidely known in the industry, but there has not been a device made thatwould interact with the patient/user in a manner that would serve twofunctions within the same device.

What is needed is a combined foot/ankle orthopedic device that is moreeconomical to build, lighter, less bulky, cosmetically appealingrequires only one fitting and serves two functions within the samedevice. Versions of this invention solve the at least one, some or allof the above-referenced problems of the prior art and save user time byeliminating the need for two fittings, giving the user of versions ofthis invention new benefits and results not found in the prior art.

This industry has constant changes and improvements, but nothing of thisnature has been developed, introduced, discussed or presented at anylevel including seminars, trade shows, advertisements, or infomercialsis known to this inventor.

The possibilities of versions of this brace/orthotic concept will nolonger limit the patient/user to the current option of two separatedevices. Not only are the current options very expensive, but typicallycumbersome for the user. The current method would require the individualto seek additional support after their injury is healed or they havebeen released from their physician to resume normal activity. This willinvolve additional costs and time for manufacturing beyond the initialvisit and cost. These additional costs and time spent are saved by thisnew concept.

No foot and/or ankle device is known to this inventor that addresses thedeficiencies in the earlier art as is used in conventional orthopedicdevices. This new, useful and unobvious invention and concept, invarious embodiments and versions, accomplishes this much neededadvantages and unexpected results as compared to conventional orthopedicdevices.

SUMMARY OF THE INVENTION

Advantages of versions of the present invention include avoidance andsolving of at least one, some, most if not all of the above problems byallowing a combined foot/ankle orthopedic device that requires only onefitting for the patient/user. Orthotics (Greek: Oρθóζ, ortho, “tostraighten” or “align”) is a specialty within the medical fieldconcerned with the design, manufacture and application of orthoses. Anorthosis (plural: orthoses) is an orthopedic device that supports orcorrects the function of a limb or the torso. An orthopaedic brace,“appliance”, or simply brace is an orthopaedic device used to:

-   -   Control, guide, limit and/or immobilize an extremity, joint or        body segment for a particular reason    -   To restrict movement in a given direction    -   To assist movement generally    -   To reduce weight bearing forces for a particular purpose    -   To aid rehabilitation from fractures after the removal of a cast    -   To otherwise correct the shape and/or function of the body, to        provide easier movement capability or reduce pain

Versions of this concept is to incorporate two functional devices intoone. This would include a custom foot orthotic with a “tunnel”manufactured in the heel (the tunnel could be partially through the heelor completely through the heel) that would accept a leg brace with aremovable plastic “stirrup” with an optional articulating ankle jointwhich allows free range of motion for ambulation (herein defined as anortho training device). Versions include optional padding.

The result of versions of this concept would be a functional,lightweight, durable medial/lateral supporting brace with removableuprights/pads that convert to a custom orthotic (arch support) toprovide support in times when full bracing is not required. One versionof this brace orthotic combination is a “tunnel” in the heel andremovable “tab” on the upright support. That results it a unique anddually functional device.

The brace combo may be manufactured as a custom molded device, but canbe designed as an “off the shelf” product if desired. This would havetremendous benefits for the general public because of the anklestabilizing and arch support functions. It would and could beappropriate for anyone that may have an ankle sprain/strain, posteriorand anterior dysfunctions, plantar fasciitis, posterior tibia tendondysfunction (with an additional strapping function), weak ankles, poorambulation, valgus/varus ankle deformities, and/or pes planus (flatfeet).

Versions of this brace have many possibilities. It can be introduced toanyone at any age under almost every possible scenario that involvestheir feet. Sports, injuries, support, recovery, are all potential usesof versions of the device and benefited by this new concept. Thesimplicity of the brace and that it will fit into just about any shoewith at least the minimum of a back strap (like a sandal) makes it veryversatile and easy to use.

The foregoing objects, benefits and advantages of versions of theinvention are illustrative of those which can be addressed by versionsof the invention and not intended to be limiting or exhaustive of thepossible advantages that can be realized. These and other advantageswill be apparent from the description herein or can be learned frompracticing versions of the invention, both as embodied herein asexamples or as modified in view of any variations which may be apparentto those of ordinary skill in the art. Therefore, the invention residesin the novel devices, methods, arrangements, systems, combinations andimprovements herein shown and described as examples and not limitedtherein.

BRIEF DESCRIPTION OF THE DRAWINGS

In the manner in which the above-recited and other advantages andobjects of the invention are obtained, a more particular description ofthe invention briefly described above will be rendered by reference tospecific embodiments thereof which are illustrated in the appendeddrawings. Understanding that these drawings depict only typicalembodiments of the invention and are not therefore to be considered tobe limiting of its scope, the invention will be described and explainedwith additional specificity and detail through the use of theaccompanying drawings in which:

FIG. 1 is a perspective view of an embodiment of a version of theinvention.

FIG. 2 is a perspective view of a preferred embodiment of a version ofthe invention.

FIG. 3 is a side view of a version of the invention.

FIG. 4 is a top view of a version of the invention.

FIG. 5 is a bottom view of a version of the invention.

FIG. 6 is a front view of a version of the invention.

FIG. 7 is back view of a version of the invention.

FIG. 8 is a perspective detail view of the tab and tunnel inattach/detach modes used in alternate embodiments of the invention.

While the present invention will be described with reference to thedetails of the embodiments of the invention shown in the drawings (andsome embodiments not shown in the drawings), these details are notintended to limit the scope of the invention. As would be known by oneof average skill in the art, such as a foot/ankle orthopedicdesigner/builder, orthopedic doctor or similar individuals,modifications may be made that are intended to be within the scope ofversions of the invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

It is also understood that whenever and/or is used in this patentapplication it means any combination or permutation of all, one, some, aplurality or none of each of the item or list mentioned, which is notintended to be limiting but merely for example and illustration. It isalso understood that (s) designates either singular or plural. It isalso understood that “or” is an inclusive “or” to include all items in alist and not intended to be limiting and means any combination orpermutation of all, one, some, a plurality or none of each of the itemor list mentioned. It is also understood that “include(s)” and/or“including” means “including but not limited to” any combination orpermutation of all, one, some, a plurality or none of each of the itemor list mentioned.

The core of the version of the basic embodiment of the invention isdepicted in FIG. 1. The basic component is at least one base 1, whichmay be any suitable shape but illustrated herein as a orthodic(orthopedic) arch support of suitable length, width and heightfabricated such that at least one base attachment 2 (attachment means ormeans for attaching) is integrated into at least one axis of the base 1.The base can be made to approximate a foot outline and about one-eighthinch thick in one layer or use a plurality of layers. The base couldalso be custom made from computer-aided foot standing pressure analysisdevices commonly known in the art. The base may be used alone or as aninsert in a shoe worn by the operator. The base attachment 2 (“tunnel”in some versions) and at least one vertical brace 3 (“stirrup” in someversions) are shaped such that the vertical brace (“tab” in someversions) may be removably attached to the base attachment and releasedif desired. The vertical brace 3 is made of any suitable material, metaland/or rubber and/or pliable plastic. At least one vertical brace legattachment (attachment means or means for attaching) means 5 is disposedonto or into the vertical brace 3.

Optional components are interior pad(s) 4 (means for padding) andvertical brace ankle pivot(s) 6 (means for pivoting).

The components may be attached, connected, linked, related, affixed,disposed on, integrated into, adjoined, combined, bonded, united,associated, joined, tied, secured, bound, releasably attached, rigidlyattached, flexibly attached, attached with rotational freedom in at oneleast axis, and/or integrated into or onto each other as desired by theoperator or manufacturer.

The attachment means may be of any suitable type—loop, aperture, glue,sewn, webbing, fastener, screw, bolt, wing-nut, weld, connector link,grommet, snap, rivet, thread, rope, twine, rod, dowel, hook, plug,connector, touch fastener (Velcro—trademarked), tunnel, tab, stirrupand/or any other means, either attached/secured permanently, temporarilyand/or releasably attached.

At least one of the basic components is necessary but a plurality may beutilized if desired for different versions of the invention. This greatimprovement over the prior art expands greatly the operator's control ofboth the ankle brace and arch support base, producing new results andreducing the fitting time of conventional arch support(s) and anklebraces when used. This saves money by allowing the ankle to heal, thenremove the vertical brace and keep the arch support which reduces twopatient/user fittings to one fitting only. Versions include the base andvertical brace able to be attached or detached manually without tools bythe operator.

Versions of the invention may be made with any and all suitablematerials desired as needed for the appropriate use and is not limitedby the type of materials that may be used. Versions are all scalable andmay be made any suitable size; large, small and/or any size as desired.

A preferred embodiment uses plastics and/or plastic injection moldingtechniques and/or plastic vacuum molding techniques, well know in theart. These non-metallic materials include, among others, conventionalpolymers such as, for example, foam padding, polystyrene, polycarbonate,polyurethane, polyethylene, phenol formaldehyde resins, polybutylene,Teflon and the like.

Versions of the device may be made of biodegradable materials to allowthe device to be disposable in a “green” manner and/or recycled.

All components may be referenced in plural for convenience, as only atleast one of all components are necessary, if desired, for properoperation and use in other embodiments. Ideally, all components (or somecomponents) are injection molded from non-metallic materials (plasticand/or rubber, including natural and/or synthetic rubber and/orrubber-like compositions) foam padding, or vacuum molded as previouslymentioned above.

To make the invention in a basic embodiment, one skilled in the artwould follow these steps (for illustration only and not intended to belimiting) but are not solely limited to these instructions. Somematerials or processes may be changed to accommodate a custom device.These fabrication steps are well known in the industry.

Foot Plate/Orthotic (Base):

-   -   1) Take cast of foot/feet (or use foot impression block).    -   2) Fill cast (or impression block) with Plaster of Paris making        a positive cast.    -   3) Remove negative casting material around mold.    -   4) Make modifications to cast as indicated for patient use.    -   5) Heat material that will be used for suction forming such as        thermoplastic or carbon, etc. . . . One piece ⅛″ heel to mid        foot, then add ⅛″ metal plate to form tunnel across heel. Place        second piece of ⅛″ over entire cast.    -   6) Vacuum form material to mold.    -   7) Allow to cool.    -   8) Mark trim lines and cut/smooth foot plate to desired shape.    -   9) Top of orthotic may have a foam, ppt, plastizote, poron,        spenco, etc. added for desired cushion cut to desired length        (may be ¾ or full foot). Glue material after cutting plate and        finish with vinyl or similar material for finished look.        Upright(s) (Vertical Support):    -   1) Use a 2×4 block of wood and make a 1″ pilot hole at one end        of the 2×4.    -   2) Cut a ¾″ (outer diameter) by 12″ (in length) PVC pipe and        glue into the hole made in the wood.    -   3) Use a 1″ hole saw and 3/16″ piece of plastic to make disc for        ankle joint.    -   4) Remove plastic from hole saw, deburr and smooth (make 4        discs).    -   5) Wrap a 1×4 with 1/16″ puff or firm foam and glue with spray        adhesive like Spray 77 to adhere foam to wood block.    -   6) Set ankle discs on top of foam.    -   7) Heat 3/16″ plastic by convectional or infrared oven to allow        for vacuum forming over 2×4 wood.    -   8) Allow to cool, and then use cast saw or similar equipment to        cut out stirrup that is 1″×5″ in length.    -   9) Smooth and deburr edges.    -   10) In center ankle, make a hole with a ¼″ drill bit.    -   11) Measure from center hole down to 3″ and make horizontal        line.    -   12) Use a heat gun or torch to heat material and bend angle to        90 degrees.    -   13) Take another joint from center of hole to 2½″ and follow        heat and bend instructions as in #12.    -   14) Take both pieces from bend to horizontal end of piece and        mark 1″. Cut excess and smooth and deburr. This will now create        the “tab” like function of the stirrup.    -   15) Use 4″ water pipe with one end capped and fill the inside        drum with Plaster of Paris.    -   16) Cut 12″ by ¾″ PVC pipe and place inside center of plaster        before setting jig (do not remove plaster from PVC pipe)    -   17) Wrap with foam like in #5 and glue.    -   18) Take 1″ ankle templates and glue to foam 1″ from cylinder        top down.    -   19) Cut ⅛″ T×16″ W×24″ L plastic    -   20) Heat and vacuum form plastic to cylinder.    -   21) Deburr and smooth upright.    -   22) Use rivets or similar to add uprights to split stirrup.        Padding (Optional):    -   1) 3/16″ soft accommodative foam such as ppt, plastizote, or        equivalent should be cut to shape of upright.    -   2) Cut two pieces equally using vinyl, leather, etc., to create        an outer covering over the 3/16″ foam pieces.    -   3) Glue together with foam on inside.    -   4) Cut remaining cover leaving a 1″ welt around outer edge.    -   5) Cut 2 pieces of self-adhesive touch fastener hook to length        of pad.    -   6) Pull adhesive backing off and adhere to pad.    -   7) Cut 4 pieces of self-adhesive touch fastener hook to length        of upright and add on one piece to inside and one piece to        outside of the upright in a vertical manner.    -   8) Add 2-20″ touch fastener straps to wrap around proximal and        distal uprights in a circumference form.    -   9) Brace is complete, subject to customization.        Follow these instructions for each brace, making adjustments as        needed. The stirrup should be attached to the tunnel by placing        tabs inside the tunnel securely in a preferred embodiment. When        use of only the foot arch support base is desired, the        patient/user does not attach (or detaches) the stirrup tabs from        the tunnel.

The primary requirements for successful use of versions of the inventionare the design parameters set by the size and/or shape of thepatient/user and size of foot, ankle and calve. These requirements mayvary from one patient to another.

To use the invention in this embodiment, the patient/user would stepinto the device with the stirrups attached, aligning the foot centeredover the weight bearing arch support and wrap the straps around thecalve. Then the patient/user puts her foot with the device into her shoe(or other suitable foot covering) and laces the shoe normally. To takeoff the device, this procedure is reversed. If only the foot archsupport base is desired, the patient/user detaches the stirrup tab(s) 10from the tunnel 20 (as depicted in FIG. 8) and inserts the arch supportinto the desired shoe, then puts her foot in the shoe. Theattachment/detachment means could also include no requirement for tools,but done completely by hand. The tunnel and tab(s) may be friction fit.

A plurality of layers can be used with elastic, plastic and/or metalliclayer(s) in any combination as desired by the user (or operator ormanufacturer) with any suitable material(s). For example, the archsupport base could made in layers to match the contour of theuser/patient's foot, using different density of foam layers. Thevertical brace pads could also be made in layers of different densitiesof foam. And the vertical uprights themselves could be made in layers(laminated) to achieve a desired stiffness. Malleable metal also may beused in versions of the invention, alone or in combination with othermaterials.

The above-referenced list(s), option(s), function(s), instruction(s),component(s), application(s), interaction(s), item(s), product(s),good(s), group(s) and sub-group(s) are merely intended as illustrationand examples, and are not intended by the inventor to in any way limitthe addition, deletion or modification of any said list(s), option(s),function(s), instruction(s), component(s), application(s),interaction(s), item(s), product(s), good(s), group(s) and sub-group(s)as might be desirable or useful to someone skilled in the art.

As will be apparent to persons skilled in the art, such as a person inthe arch support designer/manufacturer and/or ankle bracedesigner/manufacturer and/or orthodic designer or other similar-typeindividuals, various modifications and adaptations of the structure andmethod of use above-described will become readily apparent withoutdeparture from the spirit and scope of the invention, the scope of whichis defined in the claims. Although the foregoing invention has beendescribed in detail by way of illustration and example, it will beunderstood that the present invention is not limited to the particulardescription and specific embodiments described but may comprise anycombination of the above elements and variations thereof, many of whichwill be obvious to those skilled in the art. Additionally, the acts andactions of fabricating, assembling, using, and maintaining the preferredembodiment of this invention is well known by those skilled in the art.The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The presentembodiment is therefore to be considered in all respects as illustrativeand not restrictive, the scope of the invention being indicated by theclaims rather than by the foregoing description, and all changes whichcome within the meaning and range of equivalency of the claims aretherefore intended to be embraced therein.

I claim:
 1. An article of manufacture, an ortho training device for usewith a foot and ankle inside a shoe, comprising: A custom made footorthotic of a suitable length, width and height, further comprising atunnel integrated into a heel of the foot custom made orthotic and;further comprising a stirrup of a suitable length, width and height witha top end and a bottom end, further comprising a tab on the bottom end,said stirrup releasably attached to the heel of the foot orthotic viathe tab on the bottom end of the stirrup pushed into the tunnelintegrated into the heel of the custom made foot orthotic with afriction fit, and; further comprising a strap disposed on the stirruptop end, and; further comprising a pad disposed on the stirrup top end,wherein the custom made foot orthotic may be released from the stirrupvia the tab and tunnel integrated into the heel of the custom made footorthotic and used alone inside a shoe by the operator.